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Contents
History
Powder properties
Chemistries
Manufacture
Application processes
Color
History
Early 1950s -first thermoplastic powders applied onto heated metal
Late 1950s -first thermosetting powders for pipeline protection (Shell)
1962
1964
1964
1970
Features of powder
Zero VOC
Comply with environmental legislation
H&S, reduced fire risk
Densely crosslinked coating, high Tg
Good barrier & adhesion properties
Easier equipment cleaning and removal of uncured overspray
Over-sprayed powder can be recycled
high usage rates (95%)
reduced air pollution & effluent
Usually cured by thermal energy
Coating Properties
100% Solids
no VOCs
Thermosets
Film Thickness
50-100m
Melt Viscosity
10000 mPas
Product Tg
45-55C
Film Tg
60-110C
Chemistry
99% thermosetting powders
Chemistry used in a product depends upon end use
requirements.
Main binder systems currently in use:
Polyester
UV resistance
Mechanical & chemical resistance only fair
Epoxy
Chemical resistance
Poor UV durability
Polyester/epoxy (hybrid)
Powder chemistries
Main cross-linking reactions used in powder coatings are as follows:
Epoxy - carboxylic acid
Too slow for ambient-cure coatings but very widely used in powders
PE/TGIC, epoxy-polyester hybrids and many acrylics all use this scheme
N.B. TGIC is a mutagen; TOXIC labelling now required.
Hydroxyl - isocyanate
Polyurethane powders comprise OH-functional polyesters crosslinked
with isocyanate adducts
Epoxy - amine
Epoxy - phenolic
Summary of Chemistries
Epoxy
Epoxy
Polyester
Standard
Polyester
Superdurable
PU
Fluoro
GMA
Acrylic
Acrylic
Hybrid
Exterior
Durability
Very
Poor
Poor
Good
Very Good
Good
Excellent
Very
Good
Medium
Corrosion
Resistance
Very
Good
Very
Good
Good
Good
Good
Good
Good
Good
Impact
Very
Good
Very
Good
Good
Poor
Good
Good
Poor
Poor
Flexibility
Very
Good
Very
Good
Good
Medium
Good
Good
Good
Good
Adhesion
Very
Good
Very
Good
Good
Good
Very
Good
Medium
Very
Good
Very
Good
Chemical
Resistance
Very
Good
Very
Good
Good
Good
Good
Very
Good
Very
Good
Very
Good
Heat
Resistance
Very
Poor
Good
Good
Good
Good
Good
Good
Good
Abrasion
Very
Good
Good
Good
Good
Good
Good
Good
Good
Manufacture
Pre-weighing of dry RMs
Pre-mixing
Off-line tint
Extrusion (melt mixing & homogenising)
Micronising (milling)
Classification (particle size control)
Collect finished powder
QC
colour & gloss
mechanical properties
particle size
Powder Manufacture
Premix
Extrusion
Cooling
Kibbling
Milling
Sieving
Packing
Interpon
Application
Fluidized Bed Methods
Hot dipping
Earliest means of application (1950s). Immerse pre-heated substrate in
fluidized bed of powder
good all-over coverage
thick film build, poor control
Electrostatic fluidized bed
Bed contains electrodes which ionize fluidizing air; this in turn charges
powder
No pre-heating; 30-100kV
good coverage
poor control of film build
Faraday cage effects
electrical safety problems
Fluidized bed application is now little used
Application
Spray application
Most widely used means of application
Two types:
electrostatic (corona)
tribostatic (friction)
Spray application
Corona spray
Powder gun contains electrode at c.50-100kV
Ionized air molecules charge powder particles, which deposit on
earthed workpiece
Easy control of film build
Back-ionization - repulsion of free ions trapped in deposited
powder layer
Faraday cage effects - powder particles cannot penetrate
complex shapes
-V
field lines
Tribo guns commonly have a PTFE lining (bottom of tribo series, all polymeric
materials charge +ve relative to PTFE)
No Faraday cage - only weak electric field
Back-ionization onset also delayed
+V
No Field Lines
DH
Particles melt &
coalesce
Crosslinking &
hardening
Typical Tests
Gloss
Gloss measurements are made to
check that the gloss is within
allowable tolerances.
over 80 %
Semi-gloss
66% - 79%
Satin
55% - 65%
Matt
20% - 30%
Typical Tests
Film Thickness
Typical Tests
Adhesion by cross cut
A lattice pattern is cut through the coating
Typical Tests
Pencil Hardness
Typical Tests
Color Control
A spectrophotometer is used to assess
color.
Reflectance values are measured at
several wavelengths, computed and
calculations made in the computer.
DL
Red/Green
Da
Yellow/Blue
Db
Dc
Dh
Description of color
Lightness
Light colors
Dark colors
Chroma
Strong colors
Weak colors
Hue
Red, green, yellow, blue
Lightness
a* redness/greenness
b* yellowness/blueness
Tolerancing in L*a*b*
Color is measured
Limits are set
Instrumentation
Spectrophotometer
Color fingerprint i.e. Reflectance spectrum